Pallet automatic changeover system and method

Abstract

A system and method can change location pins on a pallet for an assembly line. The system may include a plurality of pallets, each pallet including at least a first and second sockets configured to receive a location pin. The system may include a pin changing unit located between a top assembly line and a lower return line. The pin changing unit may include a pin grabber configured to engage the location pin within the first socket. The pin changing unit may include a horizontal linear actuator configured to move the pin grabber and the engaged location pin into alignment with the second socket. The pin changing unit may include a vertical linear actuator configured to extend the pin grabber into engagement with the location pin and retract the pin grabber away from the location pin.

What is claimed is: 
     
       1. A system for changing location pins on a pallet for an assembly line, comprising:
 a plurality of pallets, each of the pallets including at least a first socket configured to receive a location pin and a second socket configured to receive the location pin; and 
 a pin changing unit located between a top assembly line and a lower return line, the pin changing unit comprising:
 a pin grabber configured to engage the location pin within the first socket, the pin grabber comprising a hexagonal head configured to engage and rotate a hexagonal socket of the location pin; 
 a horizontal linear actuator configured to move the pin grabber and the engaged location pin into alignment with the second socket; and 
 a vertical linear actuator configured to extend the pin grabber into engagement with the location pin and retract the pin grabber away from the location pin. 
 
 
     
     
       2. The system of  claim 1 , further comprising a sensor configured to activate the pin changing unit in response to determining that the location pin is within the first socket of a current pallet of the pallets. 
     
     
       3. The system of  claim 2 , wherein the sensor is configured to signal the system to release the current pallet in response to determining that the location pin is within the second socket of the current pallet. 
     
     
       4. The system of  claim 1 , further comprising a pallet stopper configured to stop the pallet at the pin changing unit, wherein the pallet stopper comprises an alignment rod that engages an opening in the pallet to align the pallet with the pin changing unit. 
     
     
       5. The system of  claim 1 , further comprising a controller configured to:
 receive an indication of a part model for a queued part; and 
 select the first socket and the second socket based on the part model for the pallet corresponding to the queued part. 
 
     
     
       6. The system of  claim 5 , further comprising a loader configured to load the queued part onto the pallet with the location pin engaging an opening of the queued part. 
     
     
       7. The system of  claim 1 , wherein the pin grabber is configured to engage one or more indentations located on sides of the location pin. 
     
     
       8. The system of  claim 7 , wherein the pin grabber is configured to lift the location pin while engaged with the one or more indentations. 
     
     
       9. The system of  claim 1 , wherein the pin changing unit further includes a rotational actuator configured to rotate the pin grabber. 
     
     
       10. The system of  claim 9 , wherein the location pin includes opposing protrusions and the first socket and the second socket each include a pair of opposing vertical slots and a transverse horizontal slot, wherein the rotational actuator is configured to rotate between a first position with the opposing protrusions aligned with the pair of opposing vertical slots and a second position with the opposing protrusions aligned with the transverse horizontal slot. 
     
     
       11. A method of changing location pins on a pallet for an assembly line, comprising:
 receiving the pallet at a pin changing unit located on a return line of the assembly line; 
 extending an alignment rod through an alignment opening of the pallet to align the pallet with the pin changing unit; 
 determining a target pin location for the pallet based on a part to be received on the pallet; 
 determining, via an optical sensor, whether the pallet includes a location pin at the target pin location; and 
 retracting the alignment rod to release the pallet from the pin changing unit in response to determining that the pallet includes the location pin at the pin location. 
 
     
     
       12. The method of  claim 11 , further comprising activating the pin changing unit to move the location pin from a source pin location to the target pin location in response to determining that the pallet does not include the location pin at the target pin location. 
     
     
       13. The method of  claim 12 , wherein activating the pin changing unit to move the location pin comprises:
 extending a pin grabber into engagement with the location pin at the source pin location; 
 rotating the pin grabber and the location pin between a first orientation and a second orientation; 
 retracting the pin grabber and the location pin; 
 controlling a horizontal actuator to move the pin grabber to the target pin location; 
 extending the pin grabber; 
 rotating the pin grabber and the location pin between the second orientation and the first orientation; and 
 retracting the pin grabber from the location pin. 
 
     
     
       14. The method of  claim 13 , wherein the pin grabber is configured to engage one or more indentations located on sides of the location pin. 
     
     
       15. The method of  claim 14 , wherein the pin grabber is engaged with the one or more indentations when retracting the pin grabber and the location pin. 
     
     
       16. The method of  claim 13 , wherein the location pin includes opposing protrusions, wherein a first socket at the source pin location and a second socket at the target pin location each include a pair of opposing vertical slots and a transverse horizontal slot, and wherein in the first orientation the the opposing protrusions are aligned with the transverse horizontal slot and in the second orientation the opposing protrusions are aligned with the pair of opposing vertical slots. 
     
     
       17. The method of  claim 11 , further comprising loading the part onto the pallet with the location pin engaging a surface defining an opening of the part. 
     
     
       18. An apparatus for changing location pins on a pallet for an assembly line, comprising:
 a pin grabber configured to engage a location pin within a first socket, the pin grabber comprising a hexagonal head configured to engage and rotate a hexagonal socket of the location pin; 
 a horizontal linear actuator configured to move the pin grabber and the engaged location pin into alignment with a second socket; and 
 a vertical linear actuator configured to extend the pin grabber into engagement with the location pin and retract the pin grabber away from the location pin. 
 
     
     
       19. The apparatus of  claim 18 , further comprising a sensor configured to:
 determine that the location pin is within the first socket of a current pallet; 
 activate the apparatus to move the location pin from the first socket to the second socket; and 
 release the current pallet in response to determining that the location pin is within the second socket of the current pallet. 
 
     
     
       20. The apparatus of  claim 18 , further comprising a pallet stopper configured to stop the pallet at the apparatus, wherein the pallet stopper comprises an alignment rod that engages an opening in the pallet to align the pallet with the apparatus.